Zetec conversion?

**SidewaysMk1** · 22-11-2003, 23:55

Dont think it should be in here but....

Does a 1.6 or 2.0 zetec make a good conversion cause they seem to be way down on poere in standard form.

BUt i have been offered a 1.6 zetec wid everything 'except' ecu and harness it has all the sensors(for $1000 bds... divide by $3.30 for pounds). But i think it only has 105 hp standard if so much

, what has to be done to get good hp out of this engine from both the N/A & Turbocharged routes.

Or is it a waste of time, i can get my hands on a 2l zetec yet but how much can this engine be tuned to in terms of the mods mentioned above.

thanks.

P.s. engine would go into a mk1 escort or mk1 fiesta. not yet decided.

**KillerHippy** · 23-11-2003, 13:59

DONT buy the 1.6 its

if your gonna zetec your car then get either a 1.8l or 2.0l. Its a fairly easy conversion from what i've been reading. its pretty easy to turbo aswell

into a mk1 fezzy www.zetecinside.com/xr2/stepbystep.htm
mk2 fezzy www.jimhearne.co.uk/zetecinMk2.htm

Turboing 1.8l http://www.zetec-turbo.co.uk/
2.0l http://www.zetecturbo.com/ffmprofile.htm

cheers

**KillerHippy** · 23-11-2003, 14:01

oh yeah, you can aslo just bolt a turbo head and bits onto a 1.8 zetec bottom aslong as you dont run your booost over 1bar (14psi)

cheers

**RS Yod** · 23-11-2003, 16:52

Taken from www.classicrsfords.co.uk

The above pictures are taken from an article in classic-ford magazine. more info below.

Sumps -
Escorts have a different sump to Mondeos, I believe they are aluminium so altering the sump already on the engine could be difficult. Raceline used to do exchange sumps for the conversion, but they will not reply to my e-mails as to whether they still do. Dunnel do a combined sump/engine mounts which is expensive, but I believe will mount the engine in a better position.
Engine mounts -
Raceline used to sell adapted X/flow mounts for ZETEC conversions, however, I believe this will mount the engine to far forward a mess up the balance of the car. Again the dunnel system (see above) seems the best but at £350 + vat, it should be.
Engine management -
The cheapest engine management system is through Burton at approx £370. or buy the Dunnel stage 1 kit. but Raceline also do a system. (You have to have engine management for the engine to work.)
Gearbox -
Any ford box will fit, ideally use a 2.8 Capri/XR 4 box (5 spd) because the ratios are fantastic (just drive a 2.8 Capri and you will see!). This box a slightly longer input shaft that will need shortening to fit (same dimension as the shaft from a 1.6/2L Type 9). The box is used to 160 bhp so should be strong enough.
Clutch -
There are kits from Dunnel, Burton and Raceline amongst others involving different fly wheels etc. I'm pretty sure you can hybrid a Mondeo/Escort clutch with a pinto clutch if you are on a budget.
Carbs -
Twin 40 or 45 work, and Burton, Raceline and Dunnel to inlet manifolds. Throttle bodies are the ultimate, you can adapt motor bike ones at a total cost of about £100!!!!! A throttle sensor will improve economy and pick-up on carbs.
Exhaust -
Ashley do a complete set up for a sensible price,or go for a custom made stainless system and they come with a lifetime guarantee.
Prop - A RS2000 prop should work. as the gearbox position should not be changed
Engine Bay clearance -
You either have to alter the bulk head or use a Raceline water rail. You can adapt a (smaller) pinto thermostat if you don't want a water rail or to adapt the bulkhead, but you have to drill into the block! The distributor panel will have to moved to clear the bulkhead. I have seen it (more commonly) moved on to the bulkhead or a bracket made onto the bell housing mounts (I never understood this one myself?).
Suspension -
A ZETEC is near enough the same weight as a X/flow so use the tried and tested 145 lb front springs for road use.
Brakes -
You will either have to buy a remote servo or go without a servo because the Carbs take priority over the limited space! Remember, a servo does not make the brakes better!! It only makes it easier to apply them! I am going for the no servo option and disc brakes all-round, I have no doubts she will stop extremely well.
Diffs -
An LSD is a must, ideally with turreted rear suspension. Ratios - try 3.9 to start with on 13 inch wheels.

**KillerHippy** · 23-11-2003, 17:57

do you mean here http://www.classicrsfords.co.uk/zetec.htm

cheers

**RS Yod** · 24-11-2003, 00:25

Thats exactly what I mean, I didnt claim to type it all myself ??

Yodi

**KillerHippy** · 24-11-2003, 00:30

Thats exactly what I mean, I didnt claim to type it all myself ??

i never said you did

just thought it would be more helpful with the pics mentioned at the beginning of your post.

**RS Yod** · 24-11-2003, 00:32

Cool

Cofusion sorted

**duncan** · 08-01-2004, 23:38

fame at last lol

**SidewaysMk1** · 27-02-2004, 00:27

so is it possible for a 1.6 zetec to get to 200bhp at the wheels using carbs?

How many versions of the 2l zetec are they? If more than one which is the best to start with?

thanks/.

**Clint** · 27-02-2004, 00:39

so is it possible for a 1.6 zetec to get to 200bhp at the wheels using carbs?

How many versions of the 2l zetec are they? If more than one which is the best to start with?

thanks/.

I would say NO ! I like the late focus engines